Method of producing porous gypsum products



- UUMPUSIIIUNS,

COATING 0R PLASTIC.

therefore, in accordance with the method of my Iious materials and after distributing the cata- Patented Feb. 6, 1934 UNITED STATES PATENT OFFICE Hans 0. Kauifmann, Buffalo, N. Y., assig'nor to guffalo Electra-Chemical Co. Inc.. Buffalo.

No Drawing. Application September 15, 1932 Serial No. 633,385

11 Claims. (01. 106-34) This invention relates to methods of preparing the addition of materials activating the catalyst vesicular building materials prepared from cemand the period at which active evolution of oxygen entitious mixes which possess the property of occurs from the peroxide.

hardening by setting or crystallizing. As potential peroxide decomposing compggnds.

I propose o incorpora e sa s of polavgialent met- Heretofore, it has been proposed to prepare porousbuilding material from stucco byliberating als wh lble in he mix, an ave ound gases such as hydrogen or carbon dioxide by at salts o uananese, iron, co er, nicgel, g1; chemical reaction but the products so produced balt, e 0 ma e used in this connec ion.

After distributing these potentially active peroxide decomposing agents or catalysts in he possessed the disadvantage of irregularity of structure and nonhomogeneity of cellules which induces a weakness in the product, and further mix, they may be rendered ac ve y changing the introduction of substantially large quantities their chemical and physical nature whereby finely of noncementitious or non-hardening chemicals, divided colloidal or seudo-colloidal oxides or also militates against the use of such materials. h drated oxides of such met I are produced. I

It has further been suggested to use hydrogen Have ou d that such n a m'fliicai peroxide as a source of gas producing the celluchange may be induced in the potentially active lar structure so desired in building materials of this type but the difficulty of producing uniform decomposition of the peroxide and evolution of p tash 0i ammonia or 0 sin a e 91 caoxygen has hindered the wide acceptance and use p 8 f an m H1656 baths 150 the Ox e 1 hyof thi th d, drated oxide form.

The present invention provides a method for AS a e amp the following mix y be producing vesicular building materials from n d as con a n su p oportions of incementitious mixes which are adapted to set and s d e ts o the p p a of a v i u p dharden by the use of extremely minute quantities uct suitable for acoustical and in l i n purof harmless addition materials; to produce a P0585? vesicular building product characterized by minute and uniformly distributed cellules distributed throughout the product and therefore possessing uniform strength at all points. The invention further provides a method for liberating from hydrogen roxide uniformly when the mnxed wdmmentitious materials, a

method wherein a certain pen 0 n no on is provided between the mixture of the 0 en liberatin m terial with the hydrogen peroxide are added to the above mixture until a howHicE permits of a uniform mixture and distrimogeneous mass is obtained. To this mass 1 cc. bution of the substances prior to its setting or of a 10% caustic soda solution is added and after hardening, and a method wherein oxygen is uniform a a ion e en e mass is p9 ured into liberated from hydrogen peroxide admixed with the mold. After 1 minutes the decomposition 95 cementitious mixes prior to the setting or hardenof peroxide ceases and after approximately 10 ing of the mix. more minutes the plaster is set. Then after 15 In producing vesicular building products, -minutes the material can be taken out of the mold and will dry in the usual time by well known invention, I incorporate a potentially active pemethods. mo roxide decomposing agent a mix 0 cemen 1 The mold is a square 30x30 cms.; the height 7 of the material resulting from the above described lfiic agent uniformly throughout the mix so' experiment was 6.8 cms.; the height of the above rea the agent as to increase the activity thereof quantity of plaster set without the use of hydroto a degree at which the agent will actively degen peroxide is 3.3 cms. The volume of plain compose the hydrogen peroxide. Further, I plaster without the use of hydrogen peroxide in have found it is possible to regulate th e aptiya; this case will be 2,970 00s., in the case of porous tign gf the catalytic agentf'iri such fashion as gypsum, as described above, 6.120 ccs. The pcto. increase or decrease the so-call gd i wpctiqn rous gypsum has practically double the volume of 1880 ccs. Water of not too great hardness and not too g iron content,

(C8304. /2HI2O) 90 'period'that isQthepeEi'BdBTtiEQ elapsing between the plaster which indicates that of the exams-res catalyst by adding an alkaline rea ent to the bath and prefer to use soda, caustic soda, or s hydrogen peroxide 100 vol. is decomposed and all the developed oxygen retained in the material.

v Example 2 By increasing the quantity of the peroxide, larger vesicules are produced in the set material with of course a sacrifice in strength of the product. Thus by using 50 cos. of h dro en eroxide 100 volume, 1300 ccs. watgr, 0.5 gs. soa and 0.1 gs. manganous chloride with 2000 gs. aster and alkalinating with cos. of commerciaf concentrated ammonia solution with stirring a cast is produce in the 30x30 cm. mold of 8.2 ems. in height in contrast to a cast of 2.2 cms. in height when no hydrogen peroxide is used. That is 2000 gms. of the plaster produces a normal cast of 1980 ccs. while the vesicular cast has a volume of 7380 ccs.

hwflt fiinw By using the quantities of W in Examplg 2, with ccs.,of a 2% co r sulfate so utioh instead of the manganese salt a cellular cast'was obtained of 2430 cos. in volume. The texture of this material was finer and the vesicules smaller than in the product obtained in either Example 1 or 2.

E:cample 4 1800 ccs. gm

0.5 gs. Sof soap 0.5 gs. Cobalt chloride (C0C12.6H2O) 30 cos. 100 volume Hydrogen eroxide were mixed together, and

3000 gs. of plaster added and stirred uniformly to produce aslun-y.

The catalyst was activated by distributing 10 cos. of a 10% caustic soda solution throughout he mass before e plaster o ained its initial set, and the mix thereafter poured into the mold. The height of the cast was 6.2 cms. with a volume of 5580 cos. or 90% larger than the cast with straight gypsum.

It will be seen from the foregoing-that a method is provided for producing a uniform distribution of a potentially active peroxide catalyst throughout a mass of cementitious material that can be activated by changing the chemical and physical state of the catalyst to decompose the peroxide in the mix uniformly and produce a regulated vesicular structure in the mix and the set end product.

What is claimed is:

1. The process of producing cellular building products which comprises incorporating a quantity of a peroxide with a mix of cementitious material and water, distributing a potentially active catalytic peroxide decomposing agent in the mix, and thereafter rendering the catalytic agent active whereby the peroxide is decomposed and oxygen evolved uniformly throughout the mix.

2. The process of producing cellular building products which comprises incorporating a quantity of a peroxide with a cementitious mix, distributing a potentially active catalytic peroxide decomposing agent comprising a salt of a polyvalent metal in the mix, and thereafter rendering the catalytic agent active whereby the peroxide is decomposed and oxygen evolved uniformly throughout the mix.

3. The process of producing cellular building products from a cementitious mix containing water which comprises incorporating a quantity of a peroxide with the mix, distributing a potential- 1y active catalytic peroxide decomposing agent tially active catalytic peroxide decomposing agent comprising a water soluble salt of a polyvalent metal in the mix, and rendering the catalytic agent active prior to the initial set of the cementitious material of the mix whereby the peroxide is decomposed and oxygen evolved uniformly throughout the mix producing cellules therein, that remain in the material during and after the setting thereof.

5. The process of producing cellular building products from a. cementitious mix containing water, which comprises incorporating a quantity of a peroxide with the mix, distributing a potentially active catalytic peroxide decomposing agent comprising a water soluble metallic salt in the mix, and rendering the catalytic agent active prior to the initial set of the cementitious material of the mix by changing the metal of the salt to a colloidal suspension of an hydrated oxide whereby the peroxide is decomposed and oxygen evolved uniformly throughout the mix producing cellules therein that remain in the material during and after the setting thereof.

6. The process of producing cellular building products from a cementitious mix containing water, which comprises incorporating a quantity I10 of a peroxide with the mix, distributing a quantity of a water soluble manganese salt in the mix, thereafter changing the salt to a colloidal suspension of an hydrated oxide of manganese prior to the initial set of the cementitious material of the mix, whereby the peroxide is decomposed and oxygen evolved uniformly throughout the mix producing cellules therein that remain in the material during and after the setting thereof.

7. The process of producing cellular building 12 products from a cementitious mix containing water, which comprises incorporating a quantity of a peroxide with the mix, distributing a quantity of a water soluble cobalt salt in the mix, thereafter changing the salt to a colloidal suspension of an hydrated oxide of cobalt prior to the initial set of the cementitious material of the mix, whereby the peroxide is decomposed and oxygen evolved uniformly throughout the mix producing cellules therein that remain in the material during and after the setting thereof.

8. The process of producing cellular building products from a cementitious mix containing water, which comprises incorporating a quantity of a peroxide with the mix, distributing a quantity of a water soluble iron salt in the mix, thereafter changing the salt to a colloidal suspension of an hydrated oxide of iron prior to the initial set of the cementitious material of the mix, 1 whereby the peroxide is decomposed and oxygen evolved uniformly throughout the mix producing cellules therein that remain in the material during and after the setting thereof.

9. The process of producing cellular building 5 products from a cementitious mix containing water which comprises incorporating a quantity of a peroxide with the mix, distributing a quantity of a potentially active peroxide decomposing agent substantially uniformly therewith, and

. COMPOSITIONS,

COATING R PLASTIC.

thereafter changing the chemical nature of the agent to render the same active.

10. The process of producing cellular building products from a cementitious mix containing water which comprises incorporating a quantity of a. peroxide with the mix, distributing a quantity of a potentially active peroxide decomposing agent substantially uniformly therewith, and thereafter changing the physical nature of the agent to render the same active.

HANS O. KAUFFMANN. 

